Porous insert for a heating element of an oven appliance

ABSTRACT

An oven appliance is provided having a chamber for cooking food items. A heating element is also provided and, e.g., may be configured for providing heat to the food items in the chamber of the oven appliance. A porous insert is disposed within the heating element. The porous insert can, e.g., improve mixing of gas fuel and air flowing through the heating element and/or regulate the pressure and/or velocity of gas fuel and air flowing through the heating element.

FIELD OF THE INVENTION

The present subject matter relates generally to a porous insert for a heating element of an oven appliance.

BACKGROUND OF THE INVENTION

Certain oven appliances have a cabinet that defines a chamber for receipt of food items for cooking A heating element is disposed within the chamber for applying heat to the food items. The heating element can be, e.g., a gas burner that supplies thermal energy through combustion of a gas fuel. The gas burner can be constructed of a tubular element with an inlet on a first end of the element and a series of burner holes extending from a second end of the element. Gas fuel and air can enter the burner through the inlet and exit the burner through the series of burner holes.

Within the gas burner, the air and gas fuel preferably mix prior to combustion in order to form a gas fuel and air mixture. Certain gas burners include a Venturi throat for both drawing in air and assisting in mixing gas fuel and air. However, certain design constraints can limit the effectiveness of the Venturi throat for mixing gas fuel and air. For example, certain gas burners have only a limited volume of space for mixing gas fuel and air downstream of the Venturi throat. Also, the gas fuel and air can have a relatively high mass flow rate such that the gas fuel and air can mix for only a limited amount of time within the Venturi throat. Accordingly, an oven appliance with features for improving gas fuel and air mixing within a heating element of the appliance would be useful. Also, a heating element with features for improving gas fuel and air mixing within the heating element would be useful

In addition, to operate efficiently and/or safely, the discharge rate of the gas fuel and air mixture exiting the burner holes is preferably, substantially uniform. However, in certain oven appliances, the pressure and velocity of the gas fuel and air mixture within the burner can vary along the length of the burner. Such variation of pressure and velocity can cause difficulty in maintaining a uniform discharge rate for the gas fuel and air mixture exiting burner holes along the length of the burner.

Accordingly, a heating element, as may be used in an oven appliance, with features for regulating and/or adjusting the pressure and/or velocity of a gas fuel and air mixture along a length of the heating element would be useful. In addition, a heating element, as may be used in an oven appliance, with features for maintaining a substantially uniform discharge rate for a gas fuel and air mixture exiting burner holes of the heating element would be useful.

BRIEF DESCRIPTION OF THE INVENTION

Aspects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.

In a first embodiment, an oven appliance is provided. The oven appliance includes a cabinet defining a chamber for the receipt of food for cooking. The chamber is accessed through an opening defined by the cabinet. A heating element is included for providing heat to the food for cooking in the chamber. The heating element defines a conduit and extends between an inlet and an end. The conduit is configured for directing a flow of gas fuel and air from the inlet to the end of the heating element. The heating element defines a series of burner holes with a first one of the series of burner holes positioned adjacent the end of the heating element and a last one of the series of burner holes positioned away from the end of the heating element such that the series of burner holes extends away from the end of the heating element. The heating element also has a Venturi throat positioned downstream of the inlet and upstream of the last one of the series of burner holes. A porous insert is disposed within the conduit of the heating element. The porous inert is disposed downstream of the Venturi throat and upstream of the last one of the series of burner holes. The porous insert is configured for regulating the pressure and velocity of the flow of air and gas fuel through the conduit of the heating element.

In a second embodiment, an oven appliance is provided. The oven appliance includes a cabinet defining a chamber for the receipt of food for cooking. The chamber is accessed through an opening defined by the cabinet. A heating element is included for providing heat to the food for cooking in the chamber. The heating element defines a conduit and extends between an inlet and an end. The conduit is configured for directing a flow of gas fuel and air from the inlet to the end of the heating element. The heating element defines a series of burner holes with a first one of the series of burner holes positioned adjacent the end of the heating element and a last one of the series of burner holes positioned away from the end of the heating element such that the series of burner holes extends away from the end of the heating element. The heating element also defines a bend positioned downstream of the inlet and upstream of the last one of the series of burner holes such that the flow of gas fuel and air through the conduit changes direction at the bend. A porous insert is disposed within the conduit of the heating element. The porous inert is disposed downstream of the bend and upstream of the last one of the series of burner holes. The porous insert is configured for regulating the pressure and velocity of the flow of air and gas fuel through the conduit of the heating element.

In a third embodiment, a heating element is provided. The heating element includes a housing that defines a conduit and extends between an inlet and an end. The conduit is configured for directing a flow of gas fuel and air from the inlet to the end of the housing. The housing also defines a series of burner holes with a first one of the series of burner holes positioned adjacent the end of the housing and a last one of the series of burner holes positioned away from the end of the housing such that the series of burner holes extends away from the end of the housing. The housing has a Venturi throat positioned within the conduit downstream of the inlet and upstream of the last one of the series of burner holes. The housing also defines a bend downstream of the Venturi throat and upstream of the last one of the series of burner holes such that the flow of gas fuel and air through the conduit changes direction at the bend. A porous insert is disposed within the conduit of the housing. The porous inert is disposed downstream of the bend and upstream of the last one of the series of burner holes. The porous insert is configured for regulating the pressure and velocity of the flow of air and gas fuel through the conduit of the housing.

These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:

FIG. 1 provides a front perspective view of an exemplary oven range appliance according to an embodiment of the present subject matter.

FIG. 2 illustrates a side, partial cross-sectional view of the oven range of FIG. 1 and particularly shows an exemplary baking gas burner and exemplary broiling gas burner.

FIG. 3 illustrates a perspective view of the baking gas burner of FIG. 2 removed from the oven range for clarity and particularly shows an exemplary porous insert disposed within the baking gas burner.

DETAILED DESCRIPTION OF THE INVENTION

An oven appliance is provided having a chamber for cooking food items. A heating element is also provided and, e.g., may be configured for providing heat to the food items in the chamber of the oven appliance. A porous insert is disposed within the heating element. The porous insert can, e.g., improve mixing of gas fuel and air flowing through the heating element and/or regulate the pressure and/or velocity of gas fuel and air flowing through the heating element. Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.

FIGS. 1 and 2 illustrate an exemplary embodiment of a gas oven appliance 10. However, oven 10 is provided by way of example only. The present subject matter may be used with other oven configurations. For example, the present subject matter may be used with an oven defining multiple interior cavities for the receipt of food and/or having different pan or rack arrangements than what is shown in FIG. 2. Still other configurations may also be used as will be understood by one of skill in the art using the teachings disclosed herein. Also, the present subject matter may be used with other appliances as well, e.g., a grill appliance or a water heater.

Oven 10 includes an insulated cabinet 12 that includes an interior cooking chamber 14 defined by an interior surface 15 and is configured for the receipt of one or more food items to be cooked. Oven 10 includes a door 16 hingedly attached to cabinet 12. Handle 18 allows for access to chamber 14. For example, a user can pull on handle 18 to open or close door 16. Cabinet 12 also defines inlets 40 and a vent 42. Fresh air from an exterior of cabinet 12 may enter cooking chamber 14 through inlets 40. Heated air and fumes from combustion of gas fuel may exit cooking chamber 14 through vent 42.

Seal 20 provides for maintaining heat and cooking fumes within chamber 14 when door 16 is closed as shown in FIG. 2. Multiple parallel glass panes 22 provide for viewing the contents of chamber 14 when door 16 is closed and assist in insulating chamber 14. A baking rack 24 is positioned in chamber 14 for the receipt of food items or utensils containing food items. Baking rack 24 is slidably received onto embossed ribs or sliding rails 26 such that rack 24 may be conveniently moved into and out of chamber 14 when door 16 is open.

A gas fueled, bottom heating element 50 (e.g., a gas bake burner) is positioned in cabinet 12 below a protective guard 32. Bottom heating element 50 is used to heat chamber 14 for both cooking and cleaning of oven 10. A shutter 34 allows for the adjustment of air flow to feed the combustion of fuel. The size and heat output of bottom heating element 50 can be selected based on the e.g., the size of oven 10.

A gas fueled, top heating element 36 is also positioned in cabinet 12 (e.g., a gas broil burner). Top heating element 36 is used to heat chamber 14 for both cooking/broiling and cleaning of oven 10. An additional shutter 39 allows for the adjustment of air flow to feed the combustion of fuel. Like bottom heating element 50, the size and heat output of top heating element 36 can be selected based on the e.g., the size of oven 10. In alternative embodiments, an electric, microwave, halogen, or any other suitable heating element may be used instead of gas heating element 36.

The operation of oven 10 including heating elements 50 and 36 is controlled by one or more processing devices (not shown) such as a microprocessor or other device that is in communication with such components. Such processing device (used herein to refer generally to single and/or multiple processing devices) is also in communication with a temperature sensor 38 that is used to measure temperature inside chamber 14 and provide such measurements to the process device. Temperature sensor 38 is shown (in FIG. 2) in the top and rear of chamber 14. However, other locations may be used and, if desired, multiple temperature sensors may be applied as well.

FIG. 3 illustrates bottom heating element 50 of oven 10. However, it should be understood that top heating element 36 is substantially similar to bottom heating element 50 and that the features of top heating element 36 are substantially similar to the features of bottom heating element 50 shown in FIG. 3. Bottom heating element 50 has a substantially tubular housing 55. In FIG. 3, housing 55 has a circular cross-section. However, housing 55 may have any other suitable cross-section, e.g., oval or square. Housing 55 defines a conduit 51 for directing a flow of a gas fuel (e.g., natural gas, propane, or any other suitable gaseous fuel) and air. Bottom heating element 50 may be constructed of a metal or other similarly non-flammable, heat-resistant material. For example, bottom heating element 50 may be constructed of copper or steel.

Housing 55 of bottom heating element 50 extends between an inlet 52 and an end 54. Inlet 52 is configured for receipt of gas fuel and air. Inlet 52 is in fluid communication with a gas fuel supply (not shown) and receives gas fuel for combustion from the gas fuel supply. Inlet 52 is also positioned adjacent shutter 34 (FIG. 2) and in fluid communication with cooking chamber 14 via shutter 34 in order to receive air for combustion of gas fuel. Gas fuel and air entering bottom heating element 50 at inlet 52 is directed through bottom heating element 50 along conduit 51 such that conduit 51 directs a flow of gas fuel and air F through conduit 51.

End 54 of bottom heating element 50 is sealed such that the flow of gas fuel and air F through conduit 51 is substantially impeded by end 54. For example, as shown in FIG. 3, end 54 of bottom heating element 50 may be crimped to seal end 54. Other suitable mechanisms may be used to seal end 54, e.g., a cap or chemical sealant. As stated above, the flow of gas fuel and air F within conduit 51 terminates at end 54. However, in additional embodiments, end 54 may define additional hole(s) for directing gas fuel and air out of conduit 51 for combustion rather than being sealed.

The flow of gas fuel and air F through conduit 51 exits bottom heating element 50 through a series of burner holes 60 defined by bottom heating element 50. Bottom heating element 50 defines the series of burner holes 60 such that series of burner holes 60 extends from end 54 towards inlet 52. Thus, a first one 66 of the series of burner holes 60 is positioned adjacent end 54 of lower heating element 50, and a last one 68 of the series of burner holes 60 is positioned on lower heating element 50 such that last one 68 is spaced apart from end 54 and the first one 66 of the series of burner holes 60.

Upon exiting the series of burner holes 60, the gas fuel and air can, e.g., be combusted in order to generate heat for cooking food articles in oven 10 or cleaning oven 10. As shown in FIG. 2, the series of burner holes 60 (FIG. 3) extends along bottom heating element 50 such that the series of burner holes 60 directs gas fuel and air throughout the length of the cooking chamber 14. By distributing the series of burner holes 60 in such a manner, heat energy generated by combustion of the gas fuel and air exiting the series of burner holes 60 may, e.g., be evenly and/or efficiently distributed throughout cooking chamber 14.

A Venturi throat 62 is disposed within conduit 51 of bottom heating element 50. Gas fuel and air in conduit 51 preferably mixes prior to combustion in order to burn efficiently and/or fully. Venturi throat 62 is configured for mixing gas fuel and air within conduit 51. For example, gas fuel entering bottom heating element 50 from gas fuel supply (not shown) and air entering bottom heating element 50 from shutter 34 may require urging to mix prior to exiting one of the series of burner holes 60. The flow of air and gas fuel F decreases in pressure and increases in velocity while passing through Venturi throat 62. Upon exiting Venturi throat 62, the flow of air and gas fuel F increases in pressure and decreases in velocity. The changes in pressure and velocity of the flow of gas fuel and air F created by Venturi throat 62 can, e.g., assist in mixing the gas fuel and air flowing through conduit 51.

A bend 64 is also defined by bottom heating element 50. Bend 64 causes the flow of gas fuel and air F through conduit 51 to change direction. Bend 64 can, e.g., assist in mixing the gas fuel and air flowing through conduit 51. In FIG. 3, bend 64 causes the flow of gas fuel and air F through conduit 51 to change direction by about ninety degrees. However, in alternative embodiment, bend 64 may cause any suitable change direction to the flow of gas fuel and air F through conduit 51, e.g., (about thirty, forty-five, sixty, or seventy-five degrees). In additional alternative embodiments, lower heating element 50 need not include bend 64.

A porous insert 70 is disposed within conduit 51. Porous insert 70 is constructed such that porous insert 70 permits the flow of gas fuel and air F to flow through porous insert 70. However, porous insert 70 may also be required to withstand elevated temperatures within lower heating element 50. Accordingly, porous insert 70 may be constructed of, e.g., steel mesh, carbon fiber mesh, porous ceramic, or any other suitable porous material or combination of materials capable of withstanding elevated temperatures.

Porous insert 70 is positioned within conduit 51 downstream of Venturi throat 62 and upstream of the series of burner holes 60. However, in alternative embodiments, porous insert 70 may be positioned upstream of Venturi throat 62. Also, porous insert 70 is positioned downstream of bend 64. However, in alternative embodiments, porous insert 70 may be positioned upstream of bend 64.

Porous insert 70 defines a plurality of pores (not shown) for altering the flow of gas fuel and air F. As will be understood by one having skill in the art, the size of the plurality of pores may be selected such that the intake of air via shutter 34 is not excessively and/or negatively affected by porous insert 70.

Porous insert 70 can, e.g., regulate the pressure and velocity of flow of gas fuel and air F adjacent series of burner holes 60. Similarly, porous insert 70 can, e.g., regulate the mass flow rate of gas fuel and air exiting burner holes 60. Thus, porous insert can, e.g., improve efficiency of lower heating element 50 by regulating the mass flow rate of gas fuel and air exiting burner holes 60 such that the mass flow rate of gas fuel and air exiting burner holes 60 is more uniform. Also, porous insert 70 can assist in mixing the gas fuel and air of the flow of gas fuel and air F in order to improve combustion of the gas fuel and air. In addition, porous insert 70 can also act as a flame arrestor to limit and/or eliminate potential flashback combustion of gas fuel and air within conduit 51.

This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims. 

What is claimed is:
 1. An oven appliance comprising: a cabinet defining a chamber for the receipt of food for cooking, the chamber accessed through an opening defined by the cabinet; a heating element for providing heat to the food for cooking in the chamber, said heating element defining a conduit and extending between an inlet and an end, the conduit configured for directing a flow of gas fuel and air from the inlet to the end of said heating element, said heating element defining a series of burner holes with a first one of the series of burner holes positioned adjacent the end of the said heating element and a last one of the series of burner holes positioned away from the end of said heating element such that said series of burner holes extends away from the end of said heating element, said heating element also having a Venturi throat positioned downstream of the inlet and upstream of the last one of the series of burner holes; and a porous insert disposed within the conduit of said heating element, said porous inert disposed downstream of the Venturi throat and upstream of the last one of the series of burner holes, the porous insert configured for regulating the pressure and velocity of the flow of air and gas fuel through the conduit of said heating element.
 2. The appliance of claim 1, wherein said heating element defines a bend downstream of the inlet and upstream of the last one of the series of burner holes such that the flow of gas fuel and air through the conduit changes direction at the bend.
 3. The appliance of claim 2, wherein the bend is positioned downstream of the Venturi throat and upstream of said porous insert.
 4. The appliance of claim 1, wherein the chamber of said cabinet extends between a top and a bottom, said heating element being positioned adjacent the top of the chamber such that said heating element is a broiler heating element.
 5. The appliance of claim 1, wherein the chamber of said cabinet extends between a top and a bottom, said heating element being positioned adjacent the bottom of the chamber such that said heating element is a baking heating element.
 6. The appliance of claim 1, wherein said heating element is constructed of metal.
 7. The appliance of claim 1, wherein said porous insert is constructed of metal, ceramic, or carbon fiber.
 8. An oven appliance comprising: a cabinet defining a chamber for the receipt of food for cooking, the chamber accessed through an opening defined by the cabinet; a heating element for providing heat to the food for cooking in the chamber, said heating element defining a conduit and extending between an inlet and an end, the conduit configured for directing a flow of gas fuel and air from the inlet to the end of said heating element, said heating element defining a series of burner holes with a first one of the series of burner holes positioned adjacent the end of said heating element and a last one of the series of burner holes positioned away from the end of said heating element such that said series of burner holes extends away from the end of said heating element, said heating element also defining a bend positioned downstream of the inlet and upstream of the last one of the series of burner holes such that the flow of gas fuel and air through the conduit changes direction at the bend; and a porous insert disposed within the conduit of said heating element, said porous inert disposed downstream of the bend and upstream of the last one of the series of burner holes, the porous insert configured for regulating the pressure and velocity of the flow of air and gas fuel through the conduit of said heating element.
 9. The appliance of claim 8, further comprising a Venturi throat positioned within the conduit of said heating element downstream of the inlet of the conduit and upstream of said porous insert.
 10. The appliance of claim 9, wherein said Venturi throat is defined by said heating element.
 11. The appliance of claim 9, wherein said Venturi throat is positioned downstream of the inlet and upstream of the bend.
 12. The appliance of claim 8, wherein the chamber of said cabinet extends between a top and a bottom, said heating element being positioned adjacent the top of the chamber such that said heating element is a broiler heating element.
 13. The appliance of claim 8, wherein the chamber of said cabinet extends between a top and a bottom, said heating element being positioned adjacent the bottom of the chamber such that said heating element is a baking heating element.
 14. The appliance of claim 8, wherein said heating element is constructed of metal.
 15. The appliance of claim 8, wherein said porous insert is constructed of metal, ceramic, or carbon fiber.
 16. A heating element comprising: a housing defining a conduit and extending between an inlet and an end, the conduit configured for directing a flow of gas fuel and air from the inlet to the end, said housing also defining a series of burner holes with a first one of the series of burner holes positioned adjacent the end of said housing and a last one of the series of burner holes positioned away from the end of said housing such that said series of burner holes extends away from the end of said housing, said housing having a Venturi throat positioned within the conduit downstream of the inlet and upstream of the last one of the series of burner holes, said housing further defining a bend downstream of the Venturi throat and upstream of the last one of the series of burner holes such that the flow of gas fuel and air through the conduit changes direction at the bend; and a porous insert disposed within the conduit of said housing, said porous inert disposed downstream of the bend and upstream of the last one of the series of burner holes, the porous insert configured for regulating the pressure and velocity of the flow of air and gas fuel through the conduit of said housing.
 17. The heating element of claim 16, wherein said housing is constructed of metal.
 18. The heating element of claim 16, wherein said porous insert is constructed of metal, ceramic, or carbon fiber. 